Assembly
GENERAL INFORMATIONDo not allow dirt, grease, or foreign material to enter the case or transmission components during assembly. Keep the transmission case and components clean. Also make sure the tools and workbench area used for reassembly operations are equally clean.
Shop towels used for wiping off tools and your hands must be made from lint free materials. Lint will stick to transmission parts and could interfere with valve operation or even restrict fluid passages.
Lubricate transmission clutch and gear components with MOPAR ATF+4, type 9602, during reassembly. Soak clutch discs in transmission fluid before installation.
Use MOPAR Door Ease, or Ru-Glyde on piston seals and O-rings to ease installation. Petroleum jelly can also be used to lubricate and hold thrust washers and plates in position during assembly.
Do not use chassis grease, bearing grease, white grease, or similar lubricants on any part. These types of lubricants can eventually block or restrict fluid passages and valve operation. Use petroleum jelly only.
Do not force parts into place. The transmission components and sub-assemblies are easily installed by hand when properly aligned. If a part seems difficult to install, it is either misaligned or incorrectly assembled. Verify that thrust washers, thrust plates and seal rings are correctly positioned.
The planetary gear-train, front/rear clutch assemblies and oil pump are all much easier to install when the transmission case is upright. Either tilt the case upward with wood blocks, or cut a hole in the bench large enough for the intermediate shaft and rear support. Then lower the shaft and support into the hole and support the rear of the case directly on the bench.
FRONT/REAR SERVO
1. Lubricate rear servo piston seal with MOPAR Door Ease or ATF+4. Lubricate servo bore in case with ATF+4.
Rear Servo Piston:
2. Install rear servo piston in case. Position piston at slight angle to bore and insert piston with twisting motion.
Rear Servo Piston Spring And Retainer:
3. Install rear servo spring and retainer in case bore. Be sure spring is seated on piston.
Rear Servo Snap Ring:
4. Compress rear servo piston with C-clamp or Valve Spring Compressor C-3422-B and install servo piston snap ring.
5. Lubricate front servo piston components and servo bore in case with transmission fluid.
Front Servo Snap Ring:
6. Install front servo piston in bore. Carefully "run" small, suitable tool around piston ring to press it back into groove and ease installation. Rotate piston into bore at same time. Rock piston slightly to ease piston ring past snap ring groove and into bore.
7. Bottom front servo piston in bore and install servo spring
8. Install front servo piston rod guide as follows:
Front Servo Guide And Snap Ring:
a. Place Tool SP-5560 (or similar size tool) on guide and position C-clamp on tool and case.
b. Slowly compress rod guide while simultaneously easing seal ring into bore with suitable tool.
9. Install rod guide snap ring.
OVERRUNNING CLUTCH, REAR BAND, AND LOW-REVERSE DRUM
1. Install overrunning clutch components if not yet installed.
Rear Band And Link:
2. Position rear band and link in case.
Low Reverse Drum:
3. Install low-reverse drum. Slide drum through rear band, onto piston retainer hub and into engagement with overrunning clutch and race.
Low-Reverse Drum Snap Ring:
4. Install thrust washer in low-reverse drum spot-face Use petroleum jelly to hold washer in place.
5. Install snap ring that secures low-reverse drum to piston retainer hub.
Rear Band Reaction Pin:
6. Insert band reaction pin part way into case and band link.
Rear Band Levers And Strut:
7. Install rear band adjusting lever, reaction lever, and strut. Be sure levers and strut are aligned and engaged before seating band reaction pin in case.
PLANETARY GEAR-TRAIN, FRONT/REAR CLUTCH, AND FRONT BAND
1. Remove Alignment Shaft 6227-2, if installed previously.
Intermediate Shaft And Planetary Geartrain:
2. Install assembled intermediate shaft and planetary gear-train. Support shaft carefully during installation. Do not allow shaft bearing/ bushing surfaces to become nicked or scratched.
Intermediate Shaft And Thrust Plate:
3. Lubricate intermediate shaft thrust plate with petroleum jelly and install plate on shaft pilot hub.
Input Shaft Seal Ring And Thrust Washer:
4. Check input shaft front seal rings, fiber thrust washer and rear seal ring. Be ends of rear seal ring are hooked together and diagonal cut ends of front seal rings are firmly seated against each other as shown. Lubricate seal rings with petroleum jelly after checking them.
Assembling Front And Rear Clutches:
5. Assemble front and rear clutches. Align lugs on front clutch discs. Mount front clutch on rear clutch. Turn front clutch retainer back and forth until front clutch discs are fully seated on rear clutch splined hub.
Intermediate Shaft Thrust Washer:
6. Install intermediate shaft thrust washer in hub of rear clutch retainer. Use petroleum jelly to hold washer in place. Position washer so grooves are facing outward. Washer only fits one way in clutch retainer hub.
7. Place transmission case in upright position, or place blocks under front end of transmission repair stand to tilt case rearward. This makes it easier to install front/rear clutch assembly.
Front/Rear Clutch Assemblies:
8. Align discs in rear clutch. Then install and engage assembly in front planetary and driving shell. Turn clutch retainers back and forth until both clutches are seated.
9. Position front band lever in case and over servo rod guide. Then install front band lever pin in case and slide it through lever.
10. Coat threads of front band pin access plug with sealer and install it in case. Tighten plug to 17 Nm (13 ft. lbs.) torque.
Front Band And Linkage:
11. Slide front band over front clutch retainer and install front band strut and anchor.
12. Tighten front band adjusting screw until band is tight on clutch retainer. This will. hold clutches in place while oil pump is being installed. Verify that front/rear clutch assembly is still properly seated before tightening band.
OIL PUMP
Oil Pump Gasket And Pilot Studs:
1. Install oil pump Pilot Studs C-3288-B in case.
2. Install new oil pump gasket on pilot studs and seat it in case. Be sure gasket is properly aligned with fluid passages in case.
Front Clutch Thrust Washer:
3. Coat front clutch thrust washer with petroleum jelly to hold it in place. Then install washer over reaction shaft hub and seat it on pump.
CAUTION: The thrust washer bore (I.D.), is chamfered on one side. Make sure the chamfered side is installed so it faces the pump.
Reaction Shaft Seal Ring And Thrust Washer:
4. Check seal rings on reaction shaft support. Be sure rings are hooked together correctly. Also be sure fiber thrust washer is in position. Use extra petroleum jelly to hold washer in place if necessary.
5. Lubricate oil pump seals with petroleum MOPAR ATF+4, type 9602.
Oil Pump:
6. Mount oil pump on pilot studs and slide pump into case opening. Work pump into case by hand. Do not use a mallet or similar tools to seat pump.
7. Remove pilot studs and install oil pump bolts. Tighten pump bolts alternately and evenly to fully seat pump in case. Then final-tighten pump bolts to 20 Nm (15 ft. lbs.) torque.
8. Verify correct installation. Rotate input and intermediate shafts and check for bind. If bind exists, components are either mis-assembled, or not seated. Disassemble and correct as necessary before proceeding.
INPUT SHAFT END PLAY CHECK
NOTE: Overdrive unit must be installed in order to correctly measure the input shaft end-play.
1. Check input shaft end play as follows.
Checking Input Shaft End Play:
2. Attach dial indicator to converter housing. Position indicator plunger against input shaft and zero indicator.
3. Move input shaft in and out and record reading.
4. End play should be 0.86 - 2.13 mm (0.034 -0.084 inch).
5. If end play is incorrect, change intermediate shaft thrust washer. The thrust washer controls end play and is available in three thicknesses for adjustment purposes.
ACCUMULATOR, VALVE BODY, OIL PAN, AND TORQUE CONVERTER
Accumulator Piston And Springs:
1. Install accumulator inner spring, piston and outer spring.
2. Verify that [1][2]park/neutral position switch has not been installed in case. Valve body can not be installed if switch is in position.
Manual Lever Shaft Seal:
3. Install new valve body manual shaft seal in case. Lubricate seal lip and manual shaft with petroleum jelly. Start seal over shaft and into case. Seat seal with 15/16 inch, deep well socket.
4. Install valve body as follows:
a. Start park rod into park pawl. If rod will not slide past park pawl, pawl is engaged in park gear. Rotate overdrive output shaft with suitable size 12 point socket; this will free pawl and allow rod to engage.
b. Align and seat valve body on case. Be sure manual lever shaft and overdrive connector are fully seated in case.
c. Install and start all valve body attaching bolts by hand. Then tighten bolts evenly, in a diagonal pattern to 12 Nm (105 inch lbs.) torque. Do not overtighten valve body bolts. This could result in distortion and cross leakage after installation..
5. Install new filter on valve body. Tighten filter screws to 4 Nm (35 inch lbs.).
6. Install seal on [1][2]park/neutral position switch. Then install and tighten switch to 34 Nm (25 ft. lbs.).
CAUTION: If the condition of the transmission before the overhaul procedure caused excessive metallic or fiber contamination in the fluid, replace the torque converter and reverse flush the cooler(s) and cooler lines. Fluid contamination and transmission failure can result if not done.
7. Install torque converter. Use C-clamp or metal strap to hold converter in place for installation.
BAND ADJUSTMENT AND FINAL
1. Adjust front and rear bands as follows:
a. Loosen locknut on each band adjusting screw 4-5 turns.
b. Tighten both adjusting screws to 8 Nm (72 inch lbs.).
c. Back off front band adjusting screw 2-7/8 turns.
d. Back off rear band adjusting screw 2 turns.
e. Hold each adjusting screw in position and tighten locknut to 34 Nm (25 ft. lbs.) torque.
2. Install magnet in oil pan. Magnet seats on small protrusion at corner of pan.
3. Position new oil pan gasket on case and install oil pan. Tighten pan bolts to 17 Nm (13 ft. lbs.).
4. Install throttle valve and shift selector levers on valve body manual lever shaft.
5. Apply small quantity of dielectric grease to terminal pins of solenoid case connector and neutral switch.
6. Fill transmission with recommended fluid. Refer to Service Procedures section.
7. Road test vehicle to verify repair.